Planar bone replacement material and method for producing a porous body

Abstract

Planar alloplastic bone replacement material and methods comprise at least one plate for augmentation of bone defects, whereby the bone replacement material consists of a biocompatible plastic material, a biocompatible metal and/or a biocompatible metal alloy, whereby the at least one plate comprises a planar structure and comprises a plurality of pins extending outwards from the planar structure of the at least one plate, whereby the pins each comprise at least one connecting element, whereby the pins are deformable elastically and are arranged sufficiently close to each other such that pressing the surfaces of multiple plates onto each other causes the connecting elements of different plates to interlock with and/or snap into each other and the mutually interlocked and/or snapped-in plates form an open-pored body of mutually interlocked and/or snapped-in plates.

The invention claimed is: 
     
       1. Planar alloplastic bone replacement material comprising at least one plate for augmentation of bone defects, wherein the bone replacement material consists of a biocompatible plastic material, a biocompatible metal and/or a biocompatible metal alloy, wherein the at least one plate comprises a planar structure and comprises a plurality of pins extending outwards from the planar structure of the at least one plate, wherein the pins each comprise at least one connecting element, wherein the pins are deformable elastically and are arranged sufficiently close to each other such that pressing the surfaces of multiple plates onto each other causes the connecting elements of different plates to interlock with and/or snap into each other and the interlocked and/or snapped-in plates form an open-pored body of mutually interlocked and/or snapped-in plates. 
     
     
       2. The bone replacement material according to  claim 1 , wherein the connecting elements are mushrooms, hooks, undercuts, snap-in elements and/or opposite snap-in means. 
     
     
       3. The Bone replacement material according to  claim 1 , wherein the distance between the connecting elements and the planar structure of the at least one plate is between 0.3 mm and 2 mm or between 0.5 mm and 1 mm. 
     
     
       4. The bone replacement material according to  claim 1 , wherein the pins of the at least one plate extend perpendicular or at an angle between 60° and 90° out of the planar structure of the at least one plate. 
     
     
       5. The bone replacement material according to  claim 1 , wherein the connecting elements are provided on the jacket surface of the pins. 
     
     
       6. The bone replacement material according to  claim 1 , wherein plates that are pressed into each other interlock with and/or snap into each other irreversibly. 
     
     
       7. The bone replacement material according to  claim 1 , wherein the thickness of the at least one plate without projecting pins is between 0.25 mm and 1.5 mm. 
     
     
       8. The bone replacement material according to  claim 1 , wherein the at least one plate is produced with a generative 3D printing procedure. 
     
     
       9. The bone replacement material according to  claim 1 , wherein at least one of the at least one connecting elements per pin has a truncated cone shape, wherein the longitudinal axes of the pins form the longitudinal axes of the cones and wherein the jacket of the cones faces toward the outer side that faces away from the planar structure of the at least one plate. 
     
     
       10. The bone replacement material according to  claim 1 , wherein at least one of the at least one connecting elements per pin is provided in the form of a hook and/or as a mushroom head. 
     
     
       11. The bone replacement material according to  claim 1 , wherein the pins contain a circumferential groove as additional connecting element between the planar structure of one plate and at least one of the at least one connecting elements, wherein connecting elements of other plates can interlock with or snap into said groove such that no further motion of the connecting elements along the pins is possible. 
     
     
       12. The bone replacement material according to  claim 1 , wherein at least two connecting elements are arranged in succession on the jacket surface of the pins. 
     
     
       13. The bone replacement material according to  claim 1 , wherein the at least one plate is provided in the shape of a square, rectangle, trapezoid, parallelepiped and/or polygon. 
     
     
       14. The bone replacement material according to  claim 1 , wherein the planar structure of the at least one plate contains through-going pores, wherein the pores comprise no sharp-edged contours, wherein the pores in the planar structure of the plate have a free cross-section between 0.25 mm and 1 mm or between 0.3 mm and 0.9 mm. 
     
     
       15. The bone replacement material according to  claim 1 , wherein the planar structure of the at least one plate contains through-going pores, wherein the depth of the pores perpendicular to the planar structure of the at least one plate is at least 0.25 mm, or at least 0.4 mm. 
     
     
       16. The bone replacement material according to  claim 1 , wherein the at least one plate is made from biocompatible plastic material, stainless steel, titanium, a titanium alloy, tantalum, a tantalum alloy or composites of said materials. 
     
     
       17. The bone replacement material according to  claim 1 , wherein neighbouring pins, that are arranged on the same side of a first plate of the at least one plate, are situated at an appropriate distance from each other such that the pins of the first plate, after elastic deformation due to interlocking and/or snapping into a connecting element of a second plate of the at least one plate, enable at least two interlocks and/or snap-in connections to at least two further connecting elements of the second plate. 
     
     
       18. The bone replacement material according to  claim 1 , wherein the plate or at least one of the plates comprises pins just on one side and is attachable in planar manner to a bone on the other side, wherein, sharp tips are provided for this purpose that can be pushed into the bone or eyelets or boreholes are provided in the planar structure of the at least one plate by means of which the at least one plate can be screwed to a bone or attached by other means. 
     
     
       19. The bone replacement material according to  claim 1 , wherein the at least one plate or at least one of the at least one plates comprises pins on both sides. 
     
     
       20. The bone replacement material according to  claim 1 , wherein the at least one plate is mixed with inorganic or organic particulate bone replacement material and/or autologous or allogenic cancellous bone. 
     
     
       21. The bone replacement material according to  claim 1 , wherein the at least one plate is coated with one or more pharmaceutical agents from the groups of antibiotics, bisphosphonates, steroids, non-steroidal anti-inflammatory drugs, growth factors, and cytostatic agents. 
     
     
       22. The bone replacement material according to  claim 1 , wherein the at least one plate or at least one of them is provided as a semi-spherical cup or domed surface or as an arc or as a trough. 
     
     
       23. The bone replacement material according to  claim 1 , wherein the pores of the open-pored body formed from multiple plates to be interconnecting and osteoconductive, wherein the pores have a free cross-section between 0.1 mm and 1 mm or between 0.25 mm and 0.9 mm. 
     
     
       24. The bone replacement material according to  claim 1 , wherein the at least one plate can be deformed plastically or elastically in the planar structure. 
     
     
       25. The bone replacement material according to  claim 1 , wherein the pins having connecting elements are arranged in rows of three or more pins each and in that a strip of unoccupied surface of the at least one plate remains between these three or more rows each or in that a grouped or nested arrangement of pins having connecting elements is provided. 
     
     
       26. The bone replacement material according to  claim 1 , wherein the bone replacement material comprises at least one particle aside from the at least one plate, wherein the at least one particle comprises a core and at least six pins extending from the core, wherein the pins each comprise at least one connecting element that is designed in analogous manner to the connecting elements of the at least one plates such that the at least one plate and the at least one particle interlock with and/or snap into each other by pressing the connecting elements of the at least one plate and of the at least one particle onto each other, and whereby the mutually interlocked and/or snapped-in plate(s) and particle(s) form an open-pored body of mutually interlocked and/or snapped-in plate(s) and particle(s). 
     
     
       27. A method for forming a body made of a planar alloplastic bone replacement material comprising the at least one plate according to  claim 1 , in which multiple plates are pushed against each other, wherein the plates interlock with and/or snap into each other and form an open-pored body. 
     
     
       28. The method according to  claim 27 , wherein at least one of the plates is being connected to a porous three-dimensional body of a second bone replacement material by snapping-in and/or interlocking the connecting elements with the pores of the second bone replacement material, and/or at least one of the plates are being connected to a particulate third bone replacement material comprising multiple particles, whereby the particles of the third bone replacement material comprise a plurality of pins that extend from a core of the particles and have connecting elements, wherein the pins and the connecting elements of the particles of the third bone replacement material comprise the features of the pins and connecting elements of the at least one plate of the bone replacement material according to  claim 1 . 
     
     
       29. Implant material, in trauma surgery, orthopaedics or veterinary medicine, comprising the bone replacement material according to  claim 1 .